SSPC PA2-2004 Measurement of Dry Coating Thickness With Magnetic Gages PDF

SSPC-PA 2
May 1, 2004
SSPC: The Society for Protective Coatings
PAINT APPLICATION SPECIFICATION NO. 2

Measurement of Dry Coating Thickness with Magnetic Gages
adjusted on a coated part or on a shim, where the thickness
of the coating or of the shim is known.
1. Scope
1.1 GENERAL: This standard describes the procedures to
measure the thickness of a dry lm of a nonmagnetic coating
applied on a magnetic substrate using commercially available
magnetic gages. These procedures are intended to supplement
manufacturers operating instructions for the manual operation
of the gages and are not intended to replace them.
2.1.6 Coating Thickness Standard (Test Block): A smooth

ferromagnetic substrate with a nonmagnetic coating of known
thickness that is traceable to national standards.
2.1.7 Shim (Foil): A thin strip of non-magnetic plastic,
metal, or other material of known uniform thickness used to
verify the accuracy of coating dry lm thickness gages.
1.2 The procedures for adjustment and measurement are

described for two types of gages: pull-off gages (Type 1) and
electronic gages (Type 2).
2.1.8 Dry Film Thickness Reference Standard: A sample

of known thickness used to verify the accuracy of the gage,
such as coated thickness standards or shims. In some instances
with the owner's permission, a sample part (a particular piece
of coated steel) is used as a thickness standard for a particular
job.
1.3 The standard denes a procedure to determine if the

lm thickness over an extended area conforms to the minimum
and the maximum levels specied. This procedure may be
modied when measuring dry lm thickness on overcoated
surfaces (see Note 7.1).
2.1.9 Accuracy: Consistency between a measured value

and the true value of the thickness standard.
2. Description and Use
2.1.10 Structure: A unit composed of one or more connected steel members comprising a bridge, tank, ship, etc. It
is possible for a single steel shape (beam, angle, tee, pipe,
channel, etc.) to be considered a structure, if it is painted in a
shop.
2.1 DEFINITIONS
2.1.1 Gage Reading: A single reading at one point.
2.1.2 Spot Measurement: The average of at least three
gage readings made within a 4 cm (1.5 inch) diameter circle.
2.2 DESCRIPTION OF GAGES

2.1.3 Calibration: The controlled and documented process
of measuring traceable calibration standards and verifying
that the results are within the stated accuracy of the gage.
Calibrations are typically performed by the gage manufacturer
or by a qualied laboratory in a controlled environment using
a documented process. The standards used in the calibration are such that the combined uncertainties of the resultant
measurement are less than the stated accuracy of the gage.
2.2.1 Gage Types: The gage type is determined by the

specic magnetic properties employed in measuring the thickness and is not determined by the mode of data readout, i.e.
digital or analog. This standard does not cover gages that
measure the effect of eddy currents produced in the substrate
(see Note 7.2).
2.2.2 Type 1 Pull-Off Gages: In pull-off gages, a permanent magnet is brought into direct contact with the coated
surface. The force necessary to pull the magnet from the surface
is measured and interpreted as the coating thickness value on
a scale or display on the gage. Less force is required to remove
the magnet from a thick coating. The scale is nonlinear.
2.1.4 Verication: An accuracy check performed by the

user using known reference standards.
2.1.5 Adjustment: The act of aligning the gages thickness
readings to match those of a known sample in order to improve
the accuracy of the gage on a specic surface or in a specic
portion of its measurement range. Most Type 2 gages can be
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SSPC-PA 2
May 1, 2004
within the 4 cm (1.5 inch) diameter circle dening the spot.

Discard any unusually high or low gage reading that is not
repeated consistently. Take the average of the acceptable
gage readings as the spot measurement.
2.2.3 Type 2 Electronic Gages: An electronic gage uses

electronic circuitry to convert a reference signal into coating
thickness.
2.3 USE OF PAINT APPLICATION STANDARD NO. 2:
This document contains the following:
Calibration, verication, adjustment, and measurement procedures (Section 3);
Required number of measurements for conformance
to a thickness specication (Section 4);
Notes on gage principles and various factors affecting
thickness measurement (Notes 7.2 to 7.18);
A numerical example of thickness measurement over
an extended area (Appendix 1);
A numerical example of the calibration adjustment of
Type 2 gages using plastic shims (Appendix 2);
An example protocol for measuring DFT on beams
or girders (Appendix 3);
An example protocol for measuring DFT for a laydown
painted in a shop (Appendix 4);
An example protocol for measuring DFT on test panels
(Appendix 5);
An example protocol for measuring DFT of thin coatings on blast cleaned test panels (Appendix 6).
3.1.3 CALIBRATION: Gages must be calibrated by the

manufacturer or a qualied lab. A Certicate of Calibration or
other documentation showing traceability to a national standard
is required. There is no standard time interval for re-calibration,
nor is one absolutely required. Calibration intervals are usually
established based upon experience and the work environment.
A one-year calibration interval is a typical starting point suggested by gage manufacturers.
3.2 VERIFICATION OF ACCURACY
3.2.1 Measure the thickness of a series of reference standards covering the expected range of coating thickness (see
Note 7.15). To guard against measuring with an inaccurate
gage, the gage shall be checked at least at the beginning and
the end of each work shift with one or more of the reference
standards. If the gage is dropped or suspected of giving erroneous readings during the work shift, its accuracy shall be
rechecked.
3. Calibration, Verication, Adjustment, and

Measurement Procedures
3.2.2 Record the serial number of the gage, the reference

standard used, the stated thickness of the reference standard
as well as the measured thickness value obtained, and the
method used to verify gage accuracy. If the same gage, reference standard, and method of verication are used throughout
a job, they need to be recorded only once. The stated value of
the standard and the measured value must be recorded each
time calibration is veried.
3.1 GENERAL
3.1.1 ACCESS TO BARE SUBSTRATE: All gages are
affected to some degree by substrate conditions such as
roughness, shape, thickness, and composition (see Notes
7.3 to 7.8). To correct for this effect, access to the uncoated
substrate is recommended. Another option is to use separate
uncoated reference panels with similar roughness, shape,
thickness, and composition (see Notes 7.3 to 7.8). These would
be used as the bare substrate in the procedures of Sections
3.2, 3.3 and 3.4. Reference panels shall be of sufcient size
to preclude edge effects (see Note 7.9). Other conditions that
could affect measurements are described in Notes 7.10 to
7.14. Measurements on the bare substrate are taken before
the coating is applied or by masking off small representative
areas during painting. If the coating has already been applied
to the entire surface, it is customary to remove small areas of
coating for measurement and later patch them. Do not allow
the removal process to alter the condition of the substrate. If
chemical paint strippers are used, the existing prole will be
retained (see Section A2.3).
3.2.3 If readings do not agree with the reference standard,

all measurements made since the last accuracy check are
suspect. In the event of physical damage, wear, or high usage,
or after an established calibration interval, the gage shall be
rechecked for accuracy of measurement. If the gage is not
measuring accurately, it shall not be used until it is repaired
and/or recalibrated (usually by the manufacturer).
3.2.4 Shims of plastic or of non-magnetic metals which
are acceptable for verifying the accuracy of Type 2 (electronic)
gages are not used for verifying the accuracy of the Type 1
gages (see Note 7.2.1).
3.3 ADJUSTMENT AND MEASUREMENT - TYPE 1,
PULL-OFF GAGES
3.3.1 Type 1 gages have nonlinear scales and any adjusting
feature is linear in nature. Any adjustment of these gages will
limit the DFT range for which the gage will provide accurate
readings, and is not recommended.
3.1.2 SPOT MEASUREMENT: Repeated gage readings,

even at points close together, often differ due to small surface
irregularities of the coating and the substrate. Therefore, a
minimum of three (3) gage readings shall be made for each
spot measurement of either the substrate or the coating. For
each new gage reading, move the probe to a new location
3.3.2 Measure the bare substrate at a number of spots

to obtain a representative average value. This average value
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SSPC-PA 2
May 1, 2004
4.2 SPECIFYING THICKNESS: It is recommended that

both a maximum and a minimum DFT thickness be specied
for the coating. If a maximum thickness value is not explicitly
specied, the specied thickness shall be the minimum and
Section 4.3.2 would not apply.
is the base metal reading (BMR). CAUTION: the gage is not

to be adjusted to read zero on the bare substrate.
3.3.3 Measure the dry coating at the number of spots
specied in Section 4.
4.3 CONFORMANCE TO SPECIFIED THICKNESS
3.3.4 Subtract the base metal reading from the gage

reading to obtain the thickness of the coating.
4.3.1 Minimum Thickness: The average of the spot

measurements for each 10 m2 (100 ft2) area shall not be less
than the specied minimum thickness. Although no single spot
measurement in any 10 m2 (100 ft2) area shall be less than
80% of the specied minimum thickness, it is possible for any
single gage reading to under-run by a greater amount. If the
average of the spot measurements for a given 10 m2 (100
ft2) area meets or exceeds the specied minimum thickness,
but one or more spot measurements is less than 80% of the
specied minimum thickness, additional measurements will
more precisely dene the non-conforming area and facilitate
repair (see Appendix 1 and Notes 7.16 and 7.17).
3.4 ADJUSTMENT AND MEASUREMENT - TYPE 2,

ELECTRONIC GAGES
3.4.1 Different manufacturers of Type 2 (electronic) gages
follow different methods of adjustment for measuring dry lm
thickness over a blast-cleaned surface. Adjust the gage according to the manufacturers instructions (see Appendix 2).
3.4.2 Measure the dry coating at the number of spots
specied in Section 4.
4. Required Number of Measurements for

Conformance to a Thickness Specication
4.3.2 Maximum Thickness: The average of the spot

measurements for each 10 m2 (100 ft2) area shall not be more
than the specied maximum thickness. Although no single spot
measurement in any 10 m2 (100 ft2) area shall be more than
120% of the specied maximum thickness, it is possible for
any single gage reading to over-run by a greater amount. If the
average of the spot measurements for a given 10 m2 (100 ft2)
area meets or falls below the specied maximum thickness,
but one or more spot measurements is more than 120% of the
specied maximum thickness, additional measurements will
more precisely dene the non-conforming area and facilitate
repair (see Appendix 1 and Notes 7.16 and 7.17).
4.1 NUMBER OF MEASUREMENTS: Make ve (5) separate spot measurements (average of the gage readings, see
Section 3.1.2) spaced arbitrarily over each 10 m2 (100 ft2) area
to be measured. If the contracting parties agree, more than
ve (5) spot measurements may be taken in a given area (see
Section 4.1.5). The ve spot measurements shall be made for
each 10 m2 (100 ft2) of area as follows:
4.1.1 For structures not exceeding 30 m2 (300 ft2) in area,
each 10 m2 (100 ft2) area shall be measured.
5.1 To qualify under this standard, a gage must have an

accuracy at least within 5% (see Note 7.18). For thicknesses
less than 25 m (1 mil), the gage must have an accuracy at
least within 2.5 m (0.1 mil).
4.1.3 For structures exceeding 100 m2 (1,000 ft2) in area,

the rst 100 m2 (1,000 ft2) shall be measured as stated in Section 4.1.2 and for each additional 100 m2 (1,000 ft2) of area or
increment thereof, one 10 m2 (100 ft2) area shall be arbitrarily
selected by the inspector and measured.
6. Disclaimer
6.1 While every precaution is taken to ensure that all
information furnished in SSPC standards and specications is
as accurate, complete, and useful as possible, SSPC cannot
assume responsibility nor incur any obligation resulting from
the use of any materials, coatings or methods specied therein,
or of the specication or standard itself.
4.1.4 If the dry lm thickness for any 10 m2 (100 ft2) area

(see Sections 4.1.2 and 4.1.3) is not in compliance with the
requirements of Sections 4.3.1 and 4.3.2, then additional
measurements must be made to isolate the non-conforming
area, and each 10 m2 (100 ft2) area painted during that work
shift shall be measured.
6.2 This standard does not attempt to address problems

concerning safety associated with its use. The user of this
standard, as well as the user of all products or practices
described herein, is responsible for instituting appropriate
health and safety practices and for ensuring compliance with
all governmental regulations.
4.1.5 Other size areas or number of spot measurements

may be specied by the owner in the job specications as appropriate for the size and shape of the structure to be coated
(see Appendices 3, 4, 5, and 6).

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5. Accuracy
4.1.2 For structures not exceeding 100 m2 (1,000 ft2) in

area, three 10 m2 (100 ft2) areas shall be arbitrarily selected
by the inspector and measured.
7.2.2 Type 2 (electronic) gages operate on two different

magnetic principles. Some Type 2 gages use a permanent
magnet. When the magnet is brought near steel, the magnetic ux density at the tip of the magnet is increased. By
measuring this change in ux density, which varies inversely
to the distance between the magnet and the steel substrate,
the coating thickness can be determined. Hall elements and
magnet resistance elements positioned at the tip of the magnet are the most common ways that this change in magnetic
ux density is measured. Other Type 2 gages operate on the
principle of electromagnetic induction. A coil containing a soft
iron rod is energized with an AC current thereby producing
a changing magnetic eld at the tip of the probe. As with a
permanent magnet, the magnetic ux density within the rod
increases when the probe is brought near the steel substrate.
This change is easy to detect by using additional coils. The
output of these coils is related to coating thickness.
7. Notes
Notes are not requirements of this standard.
7.1 OVERCOATING: Maintenance painting often involves
application of a new coating over an existing coating system.
It is very difcult to accurately measure the DFT of this newly
applied coating using non-destructive methods. First, access
to the prole is not available, compromising the accuracy of the
BMR or the adjustment of a Type 2 gage. Second, unevenness
in the DFT of the existing coating necessitates careful mapping
of the before and after DFT readings. This unevenness also
adds to the statistical variation in trying to establish a base
DFT reading to be subtracted from the nal DFT.
A paint inspection gage (sometimes called a Tooke or PIG
gage) will give accurate DFT measurements, but it cuts through
the coating, so each measurement site must be repaired.
Ultrasound gages may be used, but their accuracy is much
less than a Type 1 or a Type 2 gage. A practical approach to
monitoring DFT when overcoating is to compute DFT from wet
lm thickness readings and the volume solids of the coating
being applied.
If the DFT of the existing coating is not too uneven, the
average DFT of the existing coating can be measured to
establish a base DFT. This base DFT is then subtracted from
the total DFT to get the thickness of the overcoat(s).
7.3 REPEATABILITY: Magnetic gages are necessarily

sensitive to very small irregularities of the coating surface or
of the steel surface directly below the probe center. Repeated
gage readings on a rough surface, even at points very close
together, frequently differ considerably, particularly for thin
lms over a rough surface with a high prole.
7.4 ZERO SETTING: Type 1 magnetic gages should not
be adjusted or set at the scale zero (0) with the gage applied
to either a rough or a smooth uncoated steel surface. Some
Type 2 gages can be adjusted to read zero (0) on an uncoated
blast cleaned surface. In all cases follow the manufacturers
recommendations.
7.2 PRINCIPLES OF THE MAGNETIC GAGE: Each of

these gages can sense and indicate only the distance between
the magnetic surface of the steel and the small rounded tip
of the magnet or probe that rests on the top surface of the
coating. For this measured distance (from the top surface of
the coating to the magnetic zero) to equal the coating thickness above the peaks, the gage readings must be corrected
for the prole of the steel surface and to a lesser extent the
composition and shape of the steel. Such correction is made
as described in Section 3.3 for Type 1 gages and Section 3.4
for Type 2 gages.
7.5 ROUGHNESS OF THE STEEL SURFACE: If the steel

surface is smooth and even, its surface plane is the effective
magnetic surface. If the steel is roughened, as by blast cleaning, the apparent or effective magnetic surface that the gage
senses is an imaginary plane located between the peaks and
valleys of the surface prole. Gages read thickness above the
imaginary magnetic plane. If a Type 1 gage is used, the coating
thickness above the peaks is obtained by subtracting the base
metal reading (see Section 3.3). With a correctly calibrated
and adjusted Type 2 gage, the reading obtained indicates the
coating thickness above the peaks (see Section 3.4).
7.2.1 Type 1 (pull-off) gages measure the force needed to

pull a small permanent magnet from the surface of the coated
steel. The magnetic force holding the magnet to the surface
varies inversely as a non-linear function of the distance between
magnet and steel, i.e., the thickness of the dry coating (plus
any other lms present).
Normally, Type 1 gages are not adjusted or reset for each
new series of measurements. Shims of sheet plastic or of nonmagnetic metals, which are permissible for adjusting Type 2
(electronic) gages should not be used for adjusting Type 1
gages. Such shims are usually fairly rigid and curved and do
not lie perfectly at, even on a smooth steel test surface. Near
the pull-off point of the measurement with any Type 1 gage,
the shim frequently springs back from the steel surface, raising
the magnet too soon and causing an erroneous reading.

7.6 DIRTY, TACKY, OR SOFT FILMS: The surface of

the coating and the probe of the gage must be free from dust,
grease, and other foreign matter in order to obtain close contact
of the probe with the coating. The accuracy of the measurement
will be affected if the coating is tacky or excessively soft. Tacky
coating lms may cause unwanted adhesion of the magnet of
a Type 1 gage. Unusually soft lms may be dented by the pressure of the probe of a Type 1 or a Type 2 gage. Soft or tacky
lms can sometimes be measured satisfactorily with Type 2
gages by putting a shim on the lm, measuring total thickness
of coating plus shim, and subtracting shim thickness.
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SSPC-PA 2
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SSPC-PA 2
May 1, 2004
When these gages are set up for verication of calibration or

measurement of coating lms, there should be no apparent
vibration.
7.6.1 Ordinary dirt and grease can be removed from a probe

by wiping with a soft cloth. Magnetic particles adhering to the
probe can be removed using an adhesive backed tape. Any
adhesive residue left on the probe must then be removed.
7.15 COATING THICKNESS STANDARDS: Coating

thickness standards consisting of coated steel plates with assigned thickness values traceable to national standards are
available from several sources, including most manufacturers
of coating thickness gages. Shims of known thicknesses are
also available from most of these same sources.
7.7 ALLOY STEEL SUBSTRATES: Differences among

most mild low-carbon steels and high strength low alloy (HSLA)
steels will not signicantly affect magnetic gage readings. For
higher alloy steels, the gage response should be checked.
Regardless of the alloy type, the gage should be adjusted to
the same steel over which the coating has been applied.
7.9 PROXIMITY TO EDGES: Magnetic gages are sensitive to geometrical discontinuities of the steel, such as holes,
corners or edges. The sensitivity to edge effects and discontinuities varies from gage to gage. Measurements closer than
2.5 cm (1 inch) from the discontinuity may not be valid unless
the gage is adjusted specically for that location.
7.10 PROXIMITY TO OTHER MASS OF STEEL: The
older two-pole gages with permanent magnets are sensitive
to the presence of another mass of steel close to the body of
the gage. This effect may extend as much as 8 cm (3 inches)
from an inside angle.
7.17 CORRECTING LOW OR HIGH THICKNESS: The

contracting parties should agree upon the method of correcting lm thicknesses that are above the maximum or below
the minimum specication. This method may be specied
in the procurement documents, may follow manufacturers
instructions, or may be a compromise reached after the nonconforming area is discovered.
7.11 TILT OF PROBE: All of the magnets or probes must

be held perpendicular to the coated surface to produce valid
measurements.
7.18 TYPE 1 PEN GAGES: Instances may arise where a

pen-type pull-off gage is the only practical method for measuring DFT. Although these gages do not normally meet the 5%
accuracy requirement, they may be used if the contracting
parties agree.
7.12 OTHER MAGNETIC FIELDS: Strong magnetic elds,

such as those from welding equipment or nearby power lines,
may interfere with operation of the gages. Residual magnetism
in the steel substrate may also affect gage readings. With xed
probe two-pole gages in such cases, it is recommended that
the readings before and after reversing the pole positions be
averaged. Other gages may require demagnetization of the
steel.
APPENDIX 1 - Numerical Example of Average

Thickness Measurement
Appendix 1 does not form a mandatory part of this standard.
The following numerical example is presented as an illustration of Section 4. Metric values are calculated equivalents
from U.S. Customary measurements. (Reference Journal of
Protective Coatings and Linings, Vol. 4, No 5, May 1987.)
Suppose this structure is 30 m2 (300 ft2) in area. Mentally
divide the surface into three equal parts, each being about
10 m2 (100 ft2).
Part A - 10 m2 (100 ft2)
Part B - 10 m2 (100 ft2)
Part C - 10 m2 (100 ft2)
7.13 EXTREMES OF TEMPERATURE: Most of the

magnetic gages operate satisfactorily at 4C and 49C (40F
and 120F). Some gages function well at much higher temperatures. However, if such temperature extremes are met
in the eld, the gage might well be checked with at least one
reference standard after both the standard and the gage are
brought to the same ambient temperature. Most electronic
gages compensate for temperature differences among the
gage, the probe, and the surface.
7.14 VIBRATION: The accuracy of the Type 1 (pull-off)
gages is affected by trafc, machinery, concussions, etc.

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7.16 VARIATION IN THICKNESS 80% of MINIMUM/

120% of MAXIMUM: In any measurement there is a certain
level of uncertainty. Two inspectors using the same gage will
not necessarily record the exact same number for a given
spot measurement using the same 4 cm (1.5 inch) diameter
circle. To allow for this natural uctuation, an individual spot
measurement is permitted to be below the specied minimum
thickness as long as other spots in the 10 m2 (100 ft2) area are
high enough to make the average thickness meet or exceed
the specied minimum thickness. Similar reasoning applies to
maximum thickness. The 80% of specied minimum and 120%
of specied maximum allow for the accuracy of the gage and
reference standards and for variations in the substrate.
7.8 CURVATURE OF STEEL SURFACE: Magnetic gage

readings may be affected by surface curvature. If the curvature
is appreciable, valid measurements may still be obtained by
adjusting the gage on a similarly curved surface.
SSPC-PA 2
May 1, 2004
thus satises the specication. Next, determine if the lowest

spot measurement, 53 m, is within 80% of the specied
minimum thickness. Eighty percent of 64 m is 51 m (0.80 x
64 = 51). Although 53 m is below the specied minimum, it
is still within 80% of it so the specication is satised. There
are individual gage readings of 38 m (1.5 mils) at spot 5 and
46 m (1.8 mils) at spot 3, both of which are clearly less than
51 m. This is allowed because only the average of the three
readings (i.e., the spot measurement) must be greater than
or equal to 51 m.
Since the structure used in this example is about 30 m2
(300 ft2), the procedure used to measure the lm thickness of
part A must be applied to both part B and part C. The measured
thickness of part B must exceed the 64 m (2.5 mils) specied
minimum, as must the thickness of part C.
To monitor the thickness of this entire 30 m2 (300 ft2)
structure, at least 45 individual gage readings must be taken,
from which 15 spot measurements are calculated. The ve spot
measurements from each 10 m2 (100 ft2) part of the structure
are used to calculate the thickness of that part.
First, measure the coating thickness on Part A. This involves

at least 15 readings of the thickness gage (see Figure A1).
Assume the specication calls for 64 m (2.5 mils) minimum
thickness. The coating thickness for area A is then the average of the ve spot measurements made on area A, namely
66 m (2.6 mils).
Spot 1
64 m
2.5 mils
Spot 2
76
3.0
Spot 3
53
2.1
Spot 4
76
3.0
Spot 5
58
2.3
Average
66 m
2.6 mils
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Considering the U.S. Customary Measurements: The

average, 2.6 mils, exceeds the specied minimum of 2.5 mils
and thus satises the specication. Next, determine if the lowest spot measurement, 2.1 mils, is within 80% of the specied
minimum thickness. Eighty percent of 2.5 mils is 2.0 mils (0.80
x 2.5 = 2.0). Although 2.1 mils is below the specied minimum,
it is still within 80 percent of it, so the specication is satised.
There are individual gage readings of 1.5 mils at spot 5 and
1.8 mils at spot 3, both of which are clearly less than 2.0 mils.
This is allowed because only the average of the three readings
(i.e. the spot measurement) must be greater than or equal to
2.0 mils.
APPENDIX 2 - Examples of the Adjustment of

Type 2 Gages Using Shims
Appendix 2 does not form a mandatory part of this
standard.
This example describes a method of adjustment to
improve the effectiveness of a Type 2 (electronic) gage on a
Considering Equivalent Metric Measurements: The average, 66 m, exceeds the specied minimum of 64 m and
FIGURE A1
PART "A" OF STRUCTURE
(APPROXIMATELY 10 M2 [100 FT2])
Part "B"

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A2.2 TWO POINT CALIBRATION ADJUSTMENT: This

example uses two shim values, one above and one below the
expected lm thickness to be measured. It should be noted that
not all lm thickness gages can be adjusted in this manner.
Assuming that the coating thickness to be measured is
100 m (4.0 mil), then shims of 250 m (10.0 mil) and 50 m
(2.0 mil) are appropriate for setting the upper and lower values
on the scale of the gage.
As protective coatings are normally applied to blast cleaned
metal surfaces, a statistical approach is required to obtain a
typical value for the adjustment. Ten readings on a shim are
sufcient to establish a reliable average value for that shim on
the roughened surface. Following the manufacturers instructions, the gage is adjusted so that the actual shim thickness
is then used to set the gage.
This procedure should be repeated for both the upper and
lower shim values.
The average of 10 readings on an intermediate shim,
approximately 100 m (4.0 mil) thick in the case described
above, will conrm that the gage has been adjusted correctly.
It is acceptable for the average reading to be within 4% of
the shim thickness.
This method ensures that the gage reads the thickness
of the coating over the peaks of the prole.
blast cleaned or otherwise roughened surface. Blast cleaning

is used throughout this example, but these methods are applicable to other types of surface preparation. A less uniform
surface, such as partially rusted hand tool cleaned steel, may
require more gage readings to achieve a satisfactory level of
statistical signicance. Since gage operation differs among
manufacturers, follow the manufacturers instructions for
adjustment of a particular gage.
A Type 2 gage needs to be adjusted to account for the
prole of the substrate in order to read the coating thickness
directly.
A portion of the substrate, after blast cleaning but prior
to coating, can be used to adjust the gage. Alternatively, an
uncoated test panel, blasted at the time the structure was blast
cleaned and having a prole representative of the structure
can be used to adjust the gage provided the test panel is of
material with similar magnetic properties and geometry as the
substrate to be measured. If this is not available then a correction value can be applied to a smooth surface adjustment
as described below.
Three adjustment techniques can be used depending
on the capability and features of the gage to be used for the
inspection. Note that due to the statistical variation produced
by a roughened surface, individual readings taken using these
three methods may not perfectly agree.
The rst two examples describe adjustment and verication
to one or more shims. When shims are used, resultant gage
measurements are less accurate and must be recalculated.
For example, the accuracy of a properly calibrated gage is
probably 2%. The thickness of a shim might be accurate to
within 3%. The combined tolerance of the gage and the shim
will be 4% as given by the sum of squares formula:
A2.3 SMOOTH SURFACE CALIBRATION ADJUSTMENT: If access to the bare blast cleaned substrate is not available because the coating already covers it, a smooth surface
can be used to adjust the gage. Adjust the gage on a smooth
surface according to the manufacturers instructions.
Readings taken on the blast-cleaned substrate will be
higher than the true value by an amount dependant on the
surface prole and the gage probe design. For most applications
a correction value of 25 m (1.0 mil) is generally applicable.
Note that this value is not related to the actual surface prole
measurement. This correction value must be subtracted from
each gage reading to correct for the effect of the prole. The
resulting corrected reading represents the thickness of the
coating over the peaks.
For ne proles the correction value may be as low as 10
m (0.4 mil) but for coarse proles it could be as high as 40
m (1.6 mil). Table A2 gives approximate correction values to
be used when a blast cleaned surface is not available to adjust
the gage.
The use of coated standards to adjust gages means that
a correction value must be applied to readings as the coated
standards make use of smooth substrate surfaces.
22 + 32 = 3.6055 4
For the gage to be in agreement with the shim, the average thickness measured by the gage must be within 4% of
the shims thickness. If the average thickness measured on a
250 m (10 mil) shim is between 240 m (9.6 mils) and 260
m (10.4 mils), the gage is properly adjusted. The minimum
240 is 250 minus 4% of 250 (9.6 is 10 minus 4% of 10); the
maximum of 260 is 250 plus 4% of 250 (10.4 is 10 plus 4% of
10). [4% of 250 is 10; 4% of 10 is 0.4.]
A2.1 SINGLE POINT CALIBRATION ADJUSTMENT: This
example uses a single shim value at or close to the thickness to
be measured. The thickness range over which this adjustment
achieves the required accuracy will vary with gage design.
Assuming that the coating thickness to be measured is
100 m (4.0 mil), then a shim of approximately 100 m (4.0
mil) should be used to adjust the gage. The shim is placed on
an area of the substrate that has been blast cleaned to the
required standards, or on a blasted test coupon with a similar
surface prole.
The average of 10 readings on the shim is sufcient to
allow for the statistical variation in the blast prole.
APPENDIX 3 - Methods for Measuring Dry Film

Thickness on Steel Beams (Girders)
Appendix 3 is not a mandatory part of this standard, but it
provides two sample protocols for measuring DFT on beams
and girders.
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7-27
SSPC-PA 2
May 1, 2004
A3.3 No single spot measurement can be less than 80%

of the specied minimum DFT. No single spot measurement
can be more than 120% of the specied maximum DFT. The
average value for each surface must conform to the specied
DFT. (There will be only eight average values if the DFT of the
toe is not measured; there may be as many as 14 average
values for tall beams.)
A3.4 SAMPLE DFT DETERMINATION OF A BEAM:
In lieu of a full DFT determination of each beam, the job
specication may require only a sample DFT determination
for selected beams less than 18 m (60 ft) long. For a sample
DFT determination, the web of tall beams is not split.
A3.4.1 Beams less than 6 m (20 ft): For beams less
than 6 m (20 ft), take two spot measurements, randomly
distributed, on each of the 12 surfaces (8 surfaces if the toe
is not measured) of the beam as dened in Figure A3. Each
spot measurement must conform to the specied DFT.
A3.4.2 Beams between 6 m (20 ft) and 18 m (60 ft):
For beams between 6 m (20 ft) and 18 m (60 ft), take three
spot measurements, randomly distributed, on each of the 12
surfaces (8 surfaces if the toe is not measured) of the beam as
dened in Figure A3. Each spot measurement must conform
to the specied DFT.
TABLE A2
TYPICAL GAGE CORRECTION VALUES USING
ISO 8503 PROFILE GRADES
(SOURCE: prEN ISO 19840)1
ISO 8503
Prole Grade
Correction
Value (m)
Correction
Value (mil)
10
25
40
0.4
1.0
1.6
Fine
Medium
Coarse
A3.5 NON-CONFORMANCE: If any spot measurement

falls outside the specied range, additional measurements
may be made to dene the non-conforming area.
A3.6 RESTRICTED ACCESS: If the beam is situated
such that one or more of the surfaces are not accessible, take
measurements on each accessible surface in accordance with
Section A3.2 or Section A3.4, as specied.
International Organization for Standardization (ISO), Case Postale 56, Geneva CH-1211, Switzerland. ISO standards may be obtained
through the American National Standards Institute (ANSI), 1819 L Street NW, Suite 600 Washington DC 20036. Standards may also be
downloaded from http://www.ansi.org. The standard from which this data originates is under development and has not formally been adopted as of June 1, 2004.
On rolled beams, measurement of surfaces 2, 6, 8, and 12 may not be practical.

7-28
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A3.2 FULL DFT DETERMINATION OF A BEAM: Divide the

beam or girder into ve equal sections along its length. Identify
the 12 surfaces of the beam as shown in Figure A3 for each
section. For tall beams where the height of the beam is 91 cm
(36 inches) or more, divide the web in half along the length of
the beam. For the full DFT determination, each half of the web
is considered a separate surface. Take one spot measurement
(as dened in Section 3.1.2) on surface 1 in each of the ve
sections. The location of the surface 1 measurement within
a section is arbitrarily chosen by the inspector in each of the
ve sections. The average of these ve spot measurements
is the DFT of surface 1. Repeat for the other 11 surfaces (7
surfaces if the toe is not measured; 14 surfaces for tall beams).
The data can be reported in a format shown in Table A3.1.
A3.1 A problem for the painter in coating steel beams or

girders is providing the same uniform thickness over high and
low vertical surfaces as over horizontal surfaces. On a beam,
there are proportionately more edges that tend to have low dry
lm thickness (DFT) and inside corners that tend to have high
DFT compared to the center of the at surfaces. Each painter
usually develops a pattern of work for a specic task. Hence,
the DFT on the underside of the top ange, for example, may
be consistently on the high side or the low side of the target
DFT. This type of error is easy to detect and correct. Random
errors pose a more difcult problem. Gross errors where the
paint is obviously too thin or too thick must be corrected and
are beyond the scope of this standard.
The number of spot measurements in these protocols
may far exceed the 5 spot measurement per 10 m2 (100 ft2)
required in the standard. The full DFT determination, described
in Section A3.2, provides a very thorough inspection of the
beam. The sample DFT determination, described in Section
A3.4, allows for fewer spot measurements. The user does
not have to require a full DFT determination for every beam
in the structure. For example, the requirement may be for a
full DFT determination on one beam out of ten, or a sample
DFT determination on one beam out of ve, or a combination
of full and sample DFT determinations.
A beam has twelve different surfaces as shown in Figure
A3. Any one of these surfaces may have a DFT outside the
specied range, and hence, shall be measured. If the thickness of the ange is less than 25 mm (1 inch), the contracting
parties may choose not to measure the DFT on the toe,2 i.e.,
surfaces 2, 6, 8, and 12 of Figure A3. As an informal initial
survey, the inspector may want to check for uniformity of DFT
across each surface. Is the DFT of the ange near the llet the
same as near the toe? Is the DFT uniform across the web? The
inspector must be sure to use a gage that is not susceptible
to edge effects. Follow the gage manufacturers instructions
when measuring the edges.
SSPC-PA 2
May 1, 2004
FIGURE A.3
THE SURFACES OF A STEEL BEAM
TABLE A3
DATASHEET FOR RECORDING SPOT MEASUREMENTS AND AVERAGE DFT VALUES
FOR THE 12 SURFACES OF A BEAM OR GIRDER
Surface*
Section 1
Section 2
Section 3
Section 4
Section 5
1
2
3
4t
4b
5
6
7
8
9
10t
10b
11
12
* t = top half of web (for tall beams)
b = bottom half of web (for tall beams)
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7-29
Average
SSPC-PA 2
May 1, 2004
A4.4 SAMPLE DFT DETERMINATION: In lieu of a full

DFT determination of each painted piece as described in Section A4.2, the job specication may require only a sample DFT
determination for selected pieces.
A3.7 ATTACHMENTS: Stiffeners and other attachments

to a beam shall be arbitrarily measured at a frequency specied in the job specication.
APPENDIX 4 - Methods for Measuring Dry Film

Thickness for a Laydown of Beams, Structural
Steel, and Miscellaneous Parts AfterShop Coating
A4.4.1 Beams less than 6 m (20 ft): Follow the procedure

described in Section A3.4.1.
A4.4.2 Beams between 6 m (20 ft) and 18 m (60 ft): Follow
the procedure described in Section A3.4.2.
Appendix 4 is not a mandatory part of this standard, but

it provides two sample protocols for measuring DFT for a
laydown.
A4.4.3 Miscellaneous parts: For a miscellaneous part,

take three spot measurements, randomly distributed on the
part. Each spot measurement must conform to the specied
DFT.
A4.1 GENERAL: A laydown is a group of steel members

laid down to be painted in one shift by one painter. For inspection of a laydown, rst make a visual survey to detect areas
with obvious defects, such as poor coverage, and correct as
necessary. As an informal initial survey, the inspector may
want to check for uniformity of DFT across each surface.
A4.5 NON-CONFORMANCE: If any spot measurement

falls outside the specied range, additional measurements
may be made to dene the non-conforming area.
A4.2 FULL DFT DETERMINATION
A4.6: RESTRICTED ACCESS: If a beam or miscellaneous

part is situated such that one or more of the surfaces are not
accessible, take measurements on each accessible surface in
accordance with Section A4.2 or Section A4.4, as specied.
A4.2.1 Beam (Girder): Follow the procedure described

in Section A3.2.
A4.2.2 Miscellaneous Part: Take one spot measurement
(as dened in Section 4.1.2) on each surface of the part. If
the part has fewer than ve surfaces, take multiple spot measurements on the larger surfaces to bring the total to ve. If
the total area of the part is over 10 m2 (100 ft2), take 5 spot
measurements randomly distributed over the part for each 10 m2
(100 ft2) or fraction thereof.
A4.7 NUMBER OF BEAMS OR PARTS TO MEASURE: In

a laydown, the number of beams or parts to receive a full DFT
determination and the number to have a sample DFT determination
can be specied. For example, do a full DFT determination on a
piece painted near the beginning of the shift, near the middle of
the shift, and near the end of the shift in accordance with Section
A4.2; and perform a sample DFT determination on every third piece
in accordance with Section A4.4.
A4.3 No single spot measurement can be less than 80%

of the specied minimum DFT. No single spot measurement
can be more than 120% of the specied maximum DFT. The
average value of the spot measurements on each surface must
conform to the specied DFT. If there is only a single spot measurement on a surface, it must conform to the specied DFT.
A4.8 ATTACHMENTS: Stiffeners and other attachments

to a beam shall be arbitrarily measured at a frequency specied in the job specication.
TABLE A3.1
NUMBER OF SPOT MEASUREMENTS NEEDED ON EACH SURFACE OF A BEAM
FOR A FULL OR A SAMPLE DFT DETERMINATION
NUMBER OF SPOT MEASUREMENTS PER SURFACE
LENGTH OF BEAM
FULL DFT DETERMINATION1
less than 6 m (20 ft)

from 6 to 18 m (20 to 60 ft)
over 18 m (60 ft)
1
5
5
5
SAMPLE DFT DETERMINATION

2
3
NA
For tall beams (91 cm [36 inches]) or more, the top half and bottom half of the web are treated as separate
surfaces in a full DFT determination.
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7-30
SSPC-PA 2
May 1, 2004
APPENDIX 5 - Method for Measuring Dry Film

Thickness on Coated Steel Test Panels
APPENDIX 6 - Method for Measuring Dry Film

Thickness of Thin Coatings on Coated Steel Test
Panels that Had Been Abrasive Blast Cleaned

it provides a sample protocol for measuring DFT on coated
steel test panels.

it provides a sample protocol for measuring DFT of thin coatings on coated steel test panels that had been abrasive blast
cleaned.
A5.1 Panel Size: The test panel shall have a minimum

area of 116 cm2 (18 in2) and a maximum area of 930 cm2 (144
in2); e.g., minimum 7.5 x 15 cm (3 x 6 inch) and maximum 30
x 30 cm (12 x 12 inch).
A6.1 A coating is dened as thin if the dry lm thickness

(DFT) is on the order of 25 micrometers (1 mil) or less. Because
the DFT is the same order as the statistical uctuations of a
DFT gage on bare blast cleaned steel, many gage readings
must be taken to get a meaningful average.
A5.2 Procedure: Use a Type 2 electronic gage. Take

two gage readings from the top third, the middle third, and the
bottom third of the test panel. Readings shall be taken at least
12 mm (one-half inch) from any edge and 25 mm (one inch)
from any other gage reading. Discard any unusually high or
low gage reading that cannot be repeated consistently. The
DFT of the test panel is the average of the six acceptable gage
readings.
A6.2 Panel Size: The test panel shall have a minimum

area of 116 cm2 (18 in2) and a maximum area of 930 cm2 (144
in2); e.g., minimum 7.5 x 15 cm (3 x 6 inch) and maximum 30
x 30 cm (12 x 12 inch).
A6.3 Procedure: Use a properly adjusted Type 2 electronic
gage. Take ten gage readings randomly distributed in the top
third of the panel. Compute the mean (average) and standard
deviation of these ten readings. Similarly, take ten readings
from the middle third and ten readings from the bottom third of
the test panel and compute their means and standard deviations. Readings shall be taken at least 12 mm (one-half inch)
from any edge and 25 mm (one inch) from any other gage
reading. Discard any unusually high or low gage reading, i.e.,
a reading that is more than three standard deviations from the
mean. The DFT of the test panel is the average of the three
means.
A5.3 Minimum Thickness: The average of the acceptable

gage readings shall be no less than the specied minimum
thickness. No single gage reading shall be less than 80% of
the specied minimum.
A5.4 Maximum Thickness: The average of the acceptable
gage readings shall be no more than the specied maximum
thickness. No single gage reading shall be more than 120%
of the specied maximum.
A5.5 Rejection: If a gage reading is less than 80% of
the specied minimum DFT or exceeds 120% of the specied maximum DFT, additional measurements may be made
to reevaluate the DFT on the area of the test panel near the
low or high gage reading. If the additional measurements indicate the DFT in the disputed area of the panel to be below
the minimum or above the maximum allowable DFT, the panel
shall be rejected.
A6.4 Minimum Thickness: The average of the means

shall be no less than the specied minimum thickness. No single
mean shall be less than 80% of the specied minimum.
A6.5 Maximum Thickness: The average of the means
shall be no more than the specied maximum thickness.
No single mean shall be more than 120% of the specied
maximum.
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7-31

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SSPC-PA 2

SSPC: The Society for Protective Coatings

PAINT APPLICATION SPECIFICATION NO. 2

2.1.6 Coating Thickness Standard (Test Block): A smooth

1.2 The procedures for adjustment and measurement are

2.1.8 Dry Film Thickness Reference Standard: A sample

1.3 The standard denes a procedure to determine if the

2.1.9 Accuracy: Consistency between a measured value

2. Description and Use

2.2 DESCRIPTION OF GAGES

2.2.1 Gage Types: The gage type is determined by the

2.1.4 Verication: An accuracy check performed by the

Copyright The Society for Protective Coatings

within the 4 cm (1.5 inch) diameter circle dening the spot.

2.2.3 Type 2 Electronic Gages: An electronic gage uses

3.1.3 CALIBRATION: Gages must be calibrated by the

3. Calibration, Verication, Adjustment, and

3.2.2 Record the serial number of the gage, the reference

3.2.3 If readings do not agree with the reference standard,

3.1.2 SPOT MEASUREMENT: Repeated gage readings,

3.3.2 Measure the bare substrate at a number of spots

Copyright The Society for Protective Coatings

4.2 SPECIFYING THICKNESS: It is recommended that

is the base metal reading (BMR). CAUTION: the gage is not

4.3 CONFORMANCE TO SPECIFIED THICKNESS

3.3.4 Subtract the base metal reading from the gage

4.3.1 Minimum Thickness: The average of the spot

3.4 ADJUSTMENT AND MEASUREMENT - TYPE 2,

4. Required Number of Measurements for

4.3.2 Maximum Thickness: The average of the spot

5.1 To qualify under this standard, a gage must have an

4.1.3 For structures exceeding 100 m2 (1,000 ft2) in area,

4.1.4 If the dry lm thickness for any 10 m2 (100 ft2) area

6.2 This standard does not attempt to address problems

4.1.5 Other size areas or number of spot measurements

Copyright The Society for Protective Coatings

4.1.2 For structures not exceeding 100 m2 (1,000 ft2) in

7.2.2 Type 2 (electronic) gages operate on two different

7.3 REPEATABILITY: Magnetic gages are necessarily

7.2 PRINCIPLES OF THE MAGNETIC GAGE: Each of

7.5 ROUGHNESS OF THE STEEL SURFACE: If the steel

7.2.1 Type 1 (pull-off) gages measure the force needed to

Copyright The Society for Protective Coatings

7.6 DIRTY, TACKY, OR SOFT FILMS: The surface of

When these gages are set up for verication of calibration or

7.6.1 Ordinary dirt and grease can be removed from a probe

7.15 COATING THICKNESS STANDARDS: Coating

7.7 ALLOY STEEL SUBSTRATES: Differences among

7.17 CORRECTING LOW OR HIGH THICKNESS: The

7.11 TILT OF PROBE: All of the magnets or probes must

7.18 TYPE 1 PEN GAGES: Instances may arise where a

7.12 OTHER MAGNETIC FIELDS: Strong magnetic elds,

APPENDIX 1 - Numerical Example of Average

7.13 EXTREMES OF TEMPERATURE: Most of the

Copyright The Society for Protective Coatings

7.16 VARIATION IN THICKNESS 80% of MINIMUM/

7.8 CURVATURE OF STEEL SURFACE: Magnetic gage

thus satises the specication. Next, determine if the lowest

First, measure the coating thickness on Part A. This involves

Considering the U.S. Customary Measurements: The

APPENDIX 2 - Examples of the Adjustment of

Copyright The Society for Protective Coatings

A2.2 TWO POINT CALIBRATION ADJUSTMENT: This